Skip to main content
SpringerLink
Log in

Formation mechanism of outlet damage in interlaminar drilling of CFRP

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Interlaminar drilling of CFRP is a specialized drilling technique that is used to maintain the structural integrity of the composite material in specific applications where high performance and durability are critical. The outlet damage has important effects on the connection reliability and service life of components. In this work, the experiments for interlaminar drilling of CFRP were designed, the thrust force during drilling process and the damage morphologies of drilling outlet were extracted, the comprehensive damage factor was proposed, and the formation mechanism of outlet damage was analyzed. In addition, the effects of machining parameters on thrust force and outlet damage were further revealed. The results show that the time-varying curve of thrust force in interlaminar drilling has the same trend as the conventional drilling, but the thrust force in conventional drilling is lower than that in interlaminar drilling. The outlet damage in interlaminar drilling is related to the fiber cutting angles (FCAs). The tear damage at the FCA of 90° is the most obvious. The burrs damage mainly occurs in the fiber layers perpendicular to the feed direction and is concentrated in the areas of FCA of 15~105° and 195~285°. The comprehensive damage factor decreases with the increase of feed rate. Increasing the spindle speed can significantly reduce the outlet damage when the feed rate is higher than 0.17 mm/r.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

References

  1. Li MJ, Gan GC, Zhang Y, Yang XJ (2018) Thermal damage of CFRP laminate in fiber laser cutting process and its impact on the mechanical behavior and strain distribution. Arch Civ Mech Eng 19:1511–1522. https://doi.org/10.1016/j.acme.2019.08.005

    Article  Google Scholar 

  2. John KM, Thirymalai Kumaran S (2020) Backup support technique towards damage-free drilling of composite materials: a review. Int J Lightweight Mater Manuf 3:357–364. https://doi.org/10.1016/j.ijlmm.2020.06.001

    Article  Google Scholar 

  3. Fu R, Jia ZY, Wang FJ, Jin Y, Sun D, Yang LJ, Cheng D (2018) Drill-exit temperature characteristics in drilling of UD and MD CFRP composites based on infrared thermography. Int J Mach Tool Manu 135:24–37. https://doi.org/10.1016/j.ijmachtools.2018.08.002

    Article  Google Scholar 

  4. Xu JY, Li C, Mi SP, An QL, Chen M (2018) Study of drilling-induced defects for CFRP composites using new criteria. Compos Struct 201:1076–1087. https://doi.org/10.1016/j.compstruct.2018.06.051

    Article  Google Scholar 

  5. Chen LM, Li MJ, Yang XJ, Li B (2020) Thermal defect characterization and heat conduction modeling during fiber laser cutting carbon fiber reinforced polymer laminates. Arch Civ Mech Eng 20:61. https://doi.org/10.1007/s43452-020-00064-8

    Article  Google Scholar 

  6. Zhang BY, Wang FJ, Wang Q, Zhao (2021) Novel fiber fracture criteria for revealing forming mechanisms of burrs and cracking at hole-exit in drilling carbon fiber reinforced plastic. J Mater Process Technol 289:116934. https://doi.org/10.1016/j.jmatprotec.2020.116934

    Article  Google Scholar 

  7. Quan YM, Sun LH (2012) Surface characteristic and its mechanism of the drilled CFRP. Adv Mater Res 591-593:333–336. https://doi.org/10.4028/www.scientific.net/AMR.591-593.333

    Article  Google Scholar 

  8. Eneyew ED, Ramulu M (2014) Experimental study of surface quality and damage when drilling unidirectional CFRP composites. J Mater Res Technol 3(4):354–362. https://doi.org/10.1016/j.jmrt.2014.10.003

    Article  Google Scholar 

  9. An QL, Cai CY, Cai XJ, Chen M (2019) Experimental investigation on the cutting mechanism and surface generation in orthogonal cutting of UD-CFRP laminates. Compos Struct 230:111441. https://doi.org/10.1016/j.compstruct.2019.111441

    Article  Google Scholar 

  10. Qiu XY, Li PN, Niu QL, Chen AH, Ouyang P, Li CP, Tae JK (2018) Influence of machining parameters and tool structure on cutting force and hole wall damage in drilling CFRP with stepped drills. Int J Adv Manuf Technol 97:857–865. https://doi.org/10.1007/s00170-018-1981-2

    Article  Google Scholar 

  11. Chen WC (1997) Some experimental investigations in the drilling of carbon fiber-reinforced plastic (CFRP) composite laminates. Int J Mach Tools Manuf 37(8):1097–1108. https://doi.org/10.1016/S0890-6955(96)00095-8

    Article  Google Scholar 

  12. Faraz A, Biermann D, Weinert K (2009) Cutting edge rounding: an innovative tool wear criterion in drilling CFRP composite laminates. Int J Mach Tools Manuf 49(15):1185–1196. https://doi.org/10.1016/j.ijmachtools.2009.08.002

    Article  Google Scholar 

  13. Davim JP, Rubio JC, Abrao A (2007) A novel approach based on digital image analysis to evaluate the delamination factor after drilling composite laminates. Compos Sci Technol 67(9):1939–1945. https://doi.org/10.1016/j.compscitech.2006.10.009

    Article  Google Scholar 

  14. Li M, Huang M, Jiang X, Kuo C, Yang X (2018) Study on burr occurrence and surface integrity during slot milling of multidirectional and plain woven CFRPs. Int J Adv Manuf Technol 97:163–173. https://doi.org/10.1007/s00170-018-1937-6

    Article  Google Scholar 

  15. Sugita N, Shu L, Kimura K, Arai G, Arai K (2019) Dedicated drill design for reduction in burr and delamination during the drilling of composite materials. CIRP Ann 68(1):89–92. https://doi.org/10.1016/j.cirp.2019.04.094

    Article  Google Scholar 

  16. Xu JY, Yin YK, Paulo Davim J, Li LF, Ji M, Geier N, er al. (2022) A critical review addressing the drilling-induced damage issues for CFRP composites. Compos Struct 294:115594. https://doi.org/10.1016/j.compstruct.2022.115594

    Article  Google Scholar 

  17. Luís Miguel PD, João Manuel RST, Victor Hugo CA, Daniel JSG (2013) Damage evaluation of drilled carbon/epoxy laminates based on area assessment methods. Compos Struct 96:576–583. https://doi.org/10.1016/j.compstruct.2012.08.003

    Article  Google Scholar 

  18. Romoli L, Lutey AHA (2019) Quality monitoring and control for drilling of CFRP laminates. J Manuf Process 40:16–26. https://doi.org/10.1016/j.jmapro.2019.02.028

    Article  Google Scholar 

  19. Wang D, Jiao F, Mao XS (2020) Mechanics of thrust force on chisel edge in carbon fiber reinforced polymer (CFRP) drilling based on bending failure theory. Int J Mech Sci 169:105336. https://doi.org/10.1016/j.ijmecsci.2019.105336

    Article  Google Scholar 

  20. Grilo TJ, Paulo RMF, Silva CRM, Davim JP (2013) Experimental delamination analyses of CFRPs using different drill geometries. Compos Part B-eng 45(1):1344–1350. https://doi.org/10.1016/j.compositesb.2012.07.057

    Article  Google Scholar 

  21. Hwang JY, Ahn DG (2020) Effects of carbide substrate properties and diamond coating morphology on drilling performance of CFRP composite. J Manuf Process 58:1274–1284. https://doi.org/10.1016/j.jmapro.2020.09.028

    Article  Google Scholar 

  22. Geier N, Szalay T, Takács M (2019) Analysis of thrust force and characteristics of uncut fibres at non-conventional oriented drilling of unidirectional carbon fibre-reinforced plastic (UD-CFRP) composite laminates. Int J Adv Manuf Technol 100:3139–3154. https://doi.org/10.1007/s00170-018-2895-8

    Article  Google Scholar 

  23. Shunmugesh K, Panneerselvam K (2016) Machinability study of carbon fiber reinforced polymer in the longitudinal and transverse direction and optimization of process parameters using PSO–GSA. End Sci Technol 19:1552–1563. https://doi.org/10.1016/j.jestch.2016.04.012

    Article  Google Scholar 

  24. Li SJ, Dai LY, Li CP, Rong C, Qiu XY, Li PN, Tae JK (2022) Prediction model of chisel edge thrust force and material damage mechanism for interlaminar-direction drilling of UD-CFRP composite laminates. Compos Struct 298:116023. https://doi.org/10.1016/j.compstruct.2022.116023

    Article  Google Scholar 

  25. Xu JY, Ji M, Davim JP, Chen M, Mansori ME, Krishnaraj V (2020) Comparative study of minimum quantity lubrication and dry drilling of CFRP/titanium stacks using TiAlN and diamond coated drills. Compos Struct 234:111727. https://doi.org/10.1016/j.compstruct.2019.111727

    Article  Google Scholar 

  26. Qiu XY, Li PN, Li CP, Niu QL, Chen AH, Ouyang PR, Tae JK (2018) Study on chisel edge drilling behavior and step drill structure on delamination in drilling CFRP. Compos Struct 203:404–413. https://doi.org/10.1016/j.compstruct.2018.07.007

    Article  Google Scholar 

  27. Durão LMP, Gonçalves DJS, Tavares JMRS, Albuquerque VHC, Aguiar Vieira A, Torres Marques A (2010) Drilling tool geometry evaluation for reinforced composite laminates. Compos Struct 92:1545–1550. https://doi.org/10.1016/j.compstruct.2009.10.035

    Article  Google Scholar 

  28. Kim J, Kim YB, Seo JW, Park HW (2019) Deburring drilled holes in CFRP composites with large pulsed electron beam (LPEB) irradiation. J Manuf Process 40:68–75. https://doi.org/10.1016/j.jmapro.2019.03.001

    Article  Google Scholar 

  29. Geier N, Póka GY, Szalay T (2018) Direct monitoring of hole damage in carbon fibre-reinforced polymer (CFRP) composites. Mater Sci Eng 448:012003. https://doi.org/10.1088/1757-899X/448/1/012003

    Article  Google Scholar 

  30. Voβ R, Henerichs M, Rupp S, Kuster F, Wegener K (2016) Evaluation of bore exit quality for fibre reinforced plastics including delamination and uncut fibres. CIRP J Manuf Sci Tec 12:56–66. https://doi.org/10.1016/j.cirpj.2015.09.003

    Article  Google Scholar 

  31. Merino-Pérez JL, Royer R, Merson E, Lockwood A, Ayvar-Soberanis S, Marshall MB (2016) Influence of workpiece constituents and cutting speed on the cutting forces developed in the conventional drilling of CFRP composites. Compos Struct 140:621–629. https://doi.org/10.1016/j.compstruct.2016.01.008

    Article  Google Scholar 

  32. Geier N, Szalay T (2017) Optimisation of process parameters for the orbital and conventional drilling of uni-directional carbon fibre-reinforced polymers (UD-CFRP). Measurement 110:319–334. https://doi.org/10.1016/j.measurement.2017.07.007

    Article  Google Scholar 

  33. Iliescu D, Gehin D, Gutierrez ME, Girot F (2010) Modeling and tool wear in drilling of CFRP. Int J Mach Tool Manu 50:204–213. https://doi.org/10.1016/j.ijmachtools.2009.10.004

    Article  Google Scholar 

  34. Zhang L, Liu Z, Tian W, Liao WH (2015) Experimental studies on the performance of different structure tools in drilling CFRP/Al alloy stacks. Int J Adv Manuf Technol 81:241–251. https://doi.org/10.1007/s00170-015-6955-z

    Article  Google Scholar 

  35. Wan M, Li SE, Yuan H, Zhang WH (2019) Cutting force modelling in machining of fiber-reinforced polymer matrix composites (PMCs): a review. Compos A: Appl Sci Manuf 117:34–55. https://doi.org/10.1016/j.compositesa.2018.11.003

    Article  Google Scholar 

  36. Barten HJ (1944) On the deflection of a cantilever beam. Q Appl Math 2(2):168–171. https://doi.org/10.2307/43633452

    Article  MathSciNet  MATH  Google Scholar 

  37. Su YL (2019) Effect of the cutting speed on the cutting mechanism in machining CFRP. Compos Struct 220:662–676. https://doi.org/10.1016/j.compstruct.2019.04.052

    Article  Google Scholar 

Download references

Funding

This study was supported by the National Natural Science Foundation of China (No. 51975208, No. 52275423, No. 52105442, and No. 51905169) and the Natural Science Foundation of Hunan Province (No. 2020JJ4301). Also, it was partially supported by the National Research Foundation of Korea (NRF) grant, which is funded by the Korean Government (MSIT) (NRF-2020R1A2B5B02001755).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Hunan University of Science and Technology, Xiangtan, 411201, China

    Shujian Li, Qingqing Li, Longyu Dai, Weiyin Liang, Changping Li, Pengnan Li & Xinyi Qiu

  2. School of Mechanical Engineering, Yeungnam University, Dae-dong, 38541, South Korea

    Tae Jo Ko

Authors
  1. Shujian Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Qingqing Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Longyu Dai
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Weiyin Liang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Changping Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Pengnan Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Xinyi Qiu
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Tae Jo Ko
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Shujian Li or Tae Jo Ko.

Ethics declarations

Competing interests

The authors declare no competing interests.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, S., Li, Q., Dai, L. et al. Formation mechanism of outlet damage in interlaminar drilling of CFRP. Int J Adv Manuf Technol 129, 5117–5133 (2023). https://doi.org/10.1007/s00170-023-12643-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-12643-z

Keywords

Search

Navigation